Method of forming continuous pipes



J. l.. REYNOLDS METHOD OF FORMING CONTINUOUS PIPEs July 29, 1952l 2 sl-lEETS-sx-IEET 1 Filed July 9, 1948 IN V EN TOR.

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METHOD OF FORMING CONTINUOUS PIEs Filed July 9, 1948 '2 si-xEETs-sl-IEET 2 Patented July 29, 1952 UNITED STATES PATENT OFFICE 2,605,202 n, i1

METHOD F FORMING CONTINUOUS IBIPESy Julian L. Reynolds, Richmond, Va. Application July 9, 1948Serial No. 37,963 c 8 Claims. (Cl. 154-83) This'invention relates to the forming of'pipev in continuous lengths rand particularly to, forming such pipe from a plurality of layers of' like or different materials'. It has been customary heretofore, in the construction of pipe lines, to prefabricate sections of pipe at a central plant and tothen transport the sections to-the site and to assemble 'them,1as by welding, bolting, or the like, into` a continuous pipev lline. Such lprevious methods involve considerable Vexpense in transporting the pipe sections and necessitated theI provision of large quantities of equipment .in the 'eld Where the pipe wasfbeing assembled.

According to the present invention only the basic materials, usually in rolls of stripmaterial, needl be transported to the iield. Such materials are then 'assembled'` Yand fabricated into a continuousy pipe in situ Without the necessity of joining short individual lengths together. '.Acco'rding to the present invention, rolls of sheet materials lsuch as metal, fabric or the like, are mounted on a travelingmachine that wraps and folds the strip sheet material into a continuous tubular pipe structure while advancing along the line where it is desired to lay thepipe. The pipe produced by the vpresent method remains stationary adjacent its ultimate location as it is being fabricated. AThe method of the present inventionY eliminates the necessity of transporting bulky pipe sections vto the ii'eld' and resultsin a lpipev structure of laniinated construction, Which is known yto lbeA stronger than lsolid-wall pipe' of the samethickness and offers; the 'further' advantage of flexibility'in that the construction ofthe pipe may be varied'from 'time to time to meet varying a method of constructing pipe utilizing readily available lmaterials Withoutv the necessity -of acquiring large and bulky machinery.

Further'objects and advantageswill appear as the vdescription v`proceeds in connection with the accompanying drawings, wherein:

Figurelis a'schematicillustration `of a machine for carrying outthe method of the present inven tion,and n y r Figure 2 is aifragment'aryfsectional-view or a portion of pipe constructed by the present methodVv and illustrating a manner of providing terminal means for connection to standardr pipe fittings.

Figure 3 is a View in elevation showing fa formed. area of the pipe extended from: thev apparatus., and resting on the ground adjacent atrench.-y As the apparatus moves to the -left the `formed,- area will be progressivelyincreased in length. *l

An apparatus for carrying out the methorciforf;l the present invention is schematically illustrated; in Figure 1 wherein asuitable frame or support member I, mounted onsuitable Wheels .-2,i s adapted to be dravvn by a suitable tractor Knot.; shown) or other motive means. Itis to be underf stood that theV machine here described is merely Y illustrative of a possible manner of carrying out.y the method of the present invention and is not. intended to be in-any Way limiting of the invention. The line along which a pipe-line is to `beled may be -previously excavated to provide the necessary ditch or trench l and theapparatus of Figure `1 is intended to be drawn along said' trench adjacent thereto whereby the finished pipe may be lowered directly into the trench-orA alongside thereof. to be later lowered and buried..

Adjacent the forward end of the framed ai standard 3`may be provided'vvth a hollow boss-4; in which a removable cylindrical mandrel!)V may?l bepositioned and clamped. Adjacent the lstrarrd-.f-A ard 3 and immediately to the rear thereof,atsuilv porting-means 6 mayA support a roll l'I o-ishe'et metal or other material. The metal stripfromrA the roll :1 may vbe trained rearwardlyV andivunr Wardly into contact with the outer surfaceofthe; mandrel 5 and by means (not shown) may: be;- wrapped and trained around themandrelso'that the opposite edges of the saidY strip 8 foi-urna joint, at 9, along the top surface` of the mandrel.' In Wrapping sheet metal of any appreciable thickness Varound a mandrel in the manner 'de-` scribed, lthe edge portions thereof` will not'fabut' each other throughout their Ventire vedgesurlfaces un'less'the edges of the strip arebeveled.` y'.l'fhisis true since the peripheral distanceabouttheiouterv` surface-of the Wrapped strip is greater tharrthe peripheral; distance around. the inner: surface; thereof and since strip'sheetimetalfis normally' supplied in roll form wherein the .Widths across opposed surfaces are equal; .In the eventra butt" joint isfdesi-red at the edges-of the Vstrip .8; trim-i. ming knives Imay be provided` to trim .theed'ge's of the strip 8 vto the bevel desired. The"e`xfa'c2i'f angle of' the bevel Will'depend upon thediameter' ofthe mandrel` employed at-the time.

IfLthe-metal from the roll 1 is-susceptiblefdi Welding or soldering, a continuous Welding or soldering means II may be positioned to so ,weld or solder the joint immediately upon the edges of the material being brought together, It will be seen that as the frame I advances the length of finished pipe extending therebehind will act to strip the Wrapped material 8 from the mandrel in a continuous manner, thus producing a continuous liner for the pipe having a longitudinal seam therein. The mandrel 5 preferably extends rearwardly beyond the point at which the seam 9 is formed and preferably to such point as inclicated at I2 in Figure 1. The liner I3, formed in the manner just described, moves rearwardly adjacent the free end of the mandrel 5 through a wrapping means comprising an upright frame I 4 xedly carried by the frame I. A rotary frame' i I5 is mounted for rotation in the frame I about an axis coincident with the axis of the mandrel 5 and liner I3.` yRolls I6 of strip sheet material are carried bythe rotary frame I5 and rotate therewith vabout the liner I3 as the latter Amoves rearwardly relative tothe'frame I. The rolls I5 willpreferably be arranged with their axes at an angle to the axis of the mandrel 5 and that angle willbe so related to the axis of the mandrel 5 that strip material carried by the rolls I5 will be Wrapped around the outer periphery` of the liner I3 to form helically wound layers of material Iir thereover with theiredges'preferably in abutting relationship. The rotary frame I5 is driven by means (not shown) in timed Vrelation to the movement of the frame I over the ground to thereby ensure proper wrapping of the strip material on the liner in the desired manner. The strip material from the rolls I5 may be sheet metal or any other desired material. Y

Asthe Vframe I moves longitudinally of the Wrappedliner thus formed, a frame I'I carrying a rotary frame I8, similar Yin all respects to frames I 4 and I 5, is causedV to advance along the wrapped liner and includes a plurality of shoes or the like |91 rThe shoes I9 may be shaped to conform to tliegouter surface of the wrappings I'Sa; and may be employed Vtov smooth or iron the said wrappings; or they may be employed to apply heat and pressure to Vset an adhesive, melt solder, or may be adapted to perform a continuous welding of the joints between the edges of ther helically Wrapped material. In the latter eventQthe shoes IS will bereplaced by'suitable welding mechanism and the'rotation' of the frame I8 would have to be sol the rollsIIi. The rolls Yof material 22 may com# prise fabric or' papeneither dry or impregnated, with any suitable niaterial.

I-l'ollowing the application of the wrappings 22x, the pipe may be further wrapped with a tension strand 23V applied by a rotatable frame 2li carryinga roll 25 ofthe strand material 23. The rotatable'frame'ZlI is carried in a stationary frameY 25 and is structurally similar to the previously described means I4, I5 and 20, 2I. The wrapping 23 would preferably be wire or other lamentary material capable of being tensioned to resist internal pressures in the pipe when the latter is put into use.

Following application of the filament 23, an extruding head 2l may be passed over the pipe and material supplied from a hopper 28 may be fed to the extruding head 21 to apply a coating of protective or insulating material` to the pipe. rIhe material applied by the 'extruding head 2l may be a paint, resin, or asphalt orthe like. Instead of applying this coating by extrusion, it could readily be sprayed or brushed onto the pipe.

If further desired, a second extruding head 28a: supplied from a hopper 29 may be arranged to' apply an exterior coating of cementitious material to the pipe. The cementitious material may be a stii mix of Portland cement with or without a mineral aggregate` or it may be any other suitable material. In many Vinstances it may be found desirable to apply anvouter coating of a quick setting cement. In the `event a sti mix-Y ture of Portland cement is employed, it will b e desirable that the'pipe be thereafter lowered directly into position in the ditch or trench provided therefor with a minimum of handling-to prevent distortion or displacement of the ce-V mentitious-coating. If desired, the pipe could be lowered into the trench before application of f the cementitious coating and the latter could be applied as the pipe approaches the bottom ofthe trench.

With the apparatus suggested, the method of the present invention can be practiced on a variety of forms of pipe. vFor instance, the liner 8 may be of any desired metal. It could be of aluminum, steel, copper or thelike and the thickness thereof would be determined by the ultimate strength required and the nature of the material to be carried by the pipe line. For certain purposes, it may be desirable to employ anodized aluminum or a strip of sheet metal having a coating of lacquer on the inner surface. to form a lap joint at 9 rather than the abutting joint' described in which suitable adhesive or sealing material could be applied to the edges of the strip 8 and caused to adhere the edges of the liner together. In the event a lap joint isdesired, the trimming knives Ii) Ycould be omitted.

For certain purposes it might also -be desirablev to form a crimped joint between the edges ofthe liner I3. In such a case, the trimming knives III could be replaced by suitable flange forming rolls, Y

whereby the material 8 when Wrapped around the mandrel 5 would present ,edgeV flangesy to each other and the structure II `could be replaced by suitable rollers or the like, to crimp the said flanges to form an interlocked seam.

The rotary frame I5 may be provided with any desired or practical number of rolls ofstrip material and the said rolls of materialrcouldrbeL similar or dissimilar materials.l For instance,l

all of the rolls I6 could contain sheetv metal, either Ysimilar to or dierent fromthe sheet metal'of of said adhesive, thus bonding the Wrappedlayen of'metal to the liner I3. v g f In like manner the material of the rolls22 For-certain purposes, it `may bedesirable` m'mld be #any chosen rnateria1 on i.combinations thereof. rEor, instancersheetsnfzresinous: material Aorvpaner or '-.cloth impregnated `.with :resins-:or asphalts .could4 be wrapped., Also fibrouszsztrips .-imnregnatedtwith siliconeevarnishesrcouldaheiused especiallyrwhereresistancefto..highzftemperatures isfde'sired, nor a fphenol ormaldehydeiimpregnant mayfbeused. HGrlass 'fabricsr crrstrands could alsojibe Wrapped om the;y pine if-thez-comtions tdwhichgthe-pipe wouldzbefsubiectedcouldifbe satisfactorily resisted ibyrsuchiafwrapping.

The :tensioning :strandsi 12:3 could also *be of any-:suitable `materialor nlaxnentsqsuch-a Wire, or,=,glass .-;or thin ribbons; of metal havinggthefref quired .tensilerstrenethi vCleafrlyany.;desired'. arrangement,or.sciiuencerii ;layersma yxbe; applied togthe pipe. Ther-various instrumentalities indicated in Figure v11i ofilgthe drawingscould berearranged to perform ltheir operations in a different sequence or any onefor more-of them-could be omitted,or;-additional mechanisms could be fadded, all depending upon the,4 nature and structure ofthe pipe -tobeultimately' constructed. K

According to thepresentnvention, thestruc.- turaof the pipe could Abe`v variedffromy timeto time in a single pipe line-'whemdifferent v'soil-or conditions of terrainareencounter-ed; Thenumber of layers 7of metalfor stiieningfmaterial-could be increased 'in localities where i great mechanical strains wouldrbe applied to fthe @pipe line. YLike:- wisemore protective coatingsA or thicken coatings could be applied where the vnature-.ofthe soil renders it highly, corrosive.

In the event .pipe structures are chosen which involve adjacent layers of dissimilar metals, it would be'desirable to in terpose a layer of insulating material therebetween to prevent destructive electrolysis. 'Themethojdof the present invention could be employedto construct ,pipes for carrying liquid under pressure or 'for carrying gases or vapors by merely varying the thickness thereof or the-number and-nature of layers appliedrover the liner. For "instance, air conductors could be constructed `having a- `liner` of very thin-.metal with subsequent :layers of, impregnated paper. Electrical conduits would/,preferably beiorxned with a liner-of insulatihggmaterialfandthe wires could be laid in the/conduit by'being fed through a hollowwmandrelfaethc conduit is ,made.

.Apipe constructed accordingtothe presentnvcntionwouldpreferablyv be -first:rnadeirrv cylindricalfzform and if different-forms are desired the fcylindrical pipe could1be pressed into4 square, y

rectangular, elliptical or othershape byfsuitable rolls or dies placedin the .desired position between any of the pairs of means 'M'. I1, '20 or 26.

It fis-entirely feasible thatrthe mandrel :fmay be other than cylindrical' toy form the liner; of the desired sectional shape in the rst instance. It is also possible to construct the inner liner by helically Wrapping sheet material in the manner of the wrap of rolls I6 directly on the mandrel 6: rotatable mandrel and thus rolled intdthe-'desired; shape. Such 3a procedurewouldlinyolve rotating ,themandrelto ywralr the linergshgeetiV there-y on, Azthenf:partially `wrapping subsequent jlagyersqon said sectionyof liner While the latterV audits mandrel;y are stationary, then-stripping the :liner from the mandr,el.;while the -latterfisgheldgxsta ,tionary. 'Such-.aprocedure, especially Wherezsubgsequent vlayers fare. also applied; in the formof fiati sheet material, would necessitatev advancing the frame I intermittentlysratherwthanscontinuously. but ,all :of the;above:suggestedrmodications of. pinelstructure could;beg-produced.v

113:l is'ldesirable .that :ancontinuo-us lpipe of the nature-i described-tbel :provided -Withigmeansf at fits terminal end to facilitate;attachmentitostands ardtpipegrttingsfior the like. .-Afxpipe constructed in accordance withjthe methods .described heretoforelwould not. readily lendiitselfitozconnections tostandard pipe fittingsfor "to `other sections-Tof similar 'pipe'. To provide Afor vsuch contingencies', it is proposed that terminal connectingzmeans bezappliedzsomewhat as 'follo-ws:

When afpoint is freached in the fabrication 'of continuous pipe where it is desired :to form .a terminal 'end thereinfor. connection to. other pipesorttingsor the like, themachinefis temporarily-'stopped and the mandrel1 5 is Y withdrawn while leaving a partially Vformed liner vand sub.- sequent' layers ina partially completed rstate.- IA short length. of. i pipe fis substituted'. lfortheman- Adrel I5.'and;iszinser.ted:into'the partially 4completed liner tov thefdesired extentzandffabrication of the pipe is resumed in the 4manner previouslyv described. However, at this time, the short section of pipezis :nothelciv stationary.v aswas the .mandrel .5 but islallowed to proceedthrough `the' machine alongwith the completed portions of the composite pipe. As "the outer .end portion of. "the moving section of pipe approaches the rolll 1 the latter .iscutland the `linerfthus Aterminated short of .the trailing' end of thepipe nipple-30. As the nipple progresses through themachine, each klayer is terminated, preferably just short ofthe end of the previouslyv Yapplied layer and when Vthe endfof the pipe has passedcompletely through the machine, astructure similar -tofthat indicatedlin-.Figure -2fwill result. Thexpipe nipple 30. may Lbe providedwith suitable threads Bil-or any other means fto :readilyadapt it for connection tothe desired structure'. VIi? desired; the pipe nipplel30 may bei held stationary and employed in place of the fmandrel'uuntil itisl desired-to form a terminal 'end in the manner described.

' During .the Wrapping of the successive layers on -thel liner I3, it is contemplated 'that suitable brakemeans be provided to tension the-*material coming from each of -therollstothereby control the tension in thelayersand during application o'f thelayers to the lterminal nipple 30 itis preferred that the tension in each layer be increased to thereby increase the frictional gripping of the liner o-n the nipple 30. If desired, a suitable adhesive may be applied between the nipple 30 and the liner I3 to ensure proper retention of the nipple in the end of the fabricated pipe.

Although -a limited number of modifications of pipe involving a limited number of steps has been disclosed herein, such disclosure is intended to be merely illustrative and in no sense limiting since it is contemplated that other forms of pipe constructed by other forms of apparatus be included in the scope of the invention and that the said invention be limited only by the appended claims. Y

.'7'A `Iclaim: Y 1. AV` method of forming pipe comprising the steps of forming a continuous tubular liner of sheetV metal, wrapping said liner with reinforcing means, said liner forming and reinforcement wrapping being performed at stations moving continuously along the length of the liner While maintaining the liner stationary against both rotary movement and movement in a direction along its length,l whereby the continuous pipe thus formed remains stationary.

2. A method of forming pipe comprising the steps of forming a continuous tubular liner of sheet metal, wrapping said liner with reinforcing means, and covering the structure thus formed with a protective layer, the said steps being performed at stations moving continuously along the length of the liner lWhile maintaining the liner stationary against both rotary movement and movement in a direction along its length, whereby the continuous pipe thus formed remains stationary. f

3. A method of forming pipe comprising .the steps of forming a :continuous tubular liner of sheet metal,-applying layers of reinforcing and protective materials about said liner, bonding said linerY and layers together, and extrudin'g a` layer of cementitious material over the pipe, the said steps being performed at stations moving continuously along the length of the liner While maintaining the liner stationary against both rotary movement and movement in a direction along its length, whereby the continuous pipe thus formedy remains stationary. Y

4. A method of forming pipe comprising, the

steps of forming a continuous tubular liner of convolutely Wrapped sheet aluminum, Wrapping said liner with a plurality of layers of reinforcing means, said liner forming and reinforcement Wrapping bein-g performed at stations moving continuously along the length of the liner While maintaining the liner stationary against both rotary movement and movement in a` direction along its length, whereby the continuous pipe thus formed remains stationary.

5. A method of forming pipe comprising'the steps of forming a continuous tubular liner of sheet metal on a moving mandrel, Wrapping said liner Witha plurality of layers of reinforcing means, and ,covering thestructure thus formed with Va protective layer, the said steps being performed at stations fixed with respect to said moving Vmandrel andmoving continuously in a direcstion along the length of the liner and While mainu taining the liner stationary against both rotary movement and movement in a direction along its length, whereby vthe continuous pipe thus formed remains stationary. Y' Y 6. A method of forming pipe comprising, the steps of forming a continuous tubular liner of sheet aluminum, vapplying layers of reinforcing and protective materials about said liner,.atfleast some of said layers being of a sheet aluminum. bonding said liner and layers together, and extruding a layer of cementitious material over the pipe, the said steps being performed at stations moving continuouslyalong the length of the liner While maintaining the liner VstationaryA against both yrotary movement and movement in a direction alongits length, whereby the continuous pipe thus formed remains stationary.

73A method of forming pipe which is to be laid -along the ground, 'comprising the' stepsof forming a continuous tubular liner of sheet metal about a horizontal mandrel While simultaneously moving the mandrel WithV respect to the ground in a horizontal fdirection along its axis and out of the liner thus 'formed and While restraining the liner against either axial or rotative move-V ment. y i

8. A method for forming continuous pipe and continuously laying the pipe along the ground, comprising the steps of vforming a continuous tubular liner of sheet metal about a horizontal mandrel While simultaneously moving the mandrel With respect tothe ground in ahorizon'tal direction along its axis andout of the liner `thus formed'and While'restraining vthe liner against either axial or rotative movement, and then forming a protective and reinforcing coating about the liner While maintaining the liner stationary with respect to the ground-so as toy form a continuous stationary pipe Vspaced above the ground, and then continuously lowering said pipe to the ground as it continues to be formed.

JULIAN L. REYNOLDS;

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS i Number Name Date 952,488 Wiggins Mar. 22, 1910 1,954,892 Russel et al.' Apr. 17, 1934 1,962,876 Reinert et al. June 12, 1934 2,302,163 y Anderson Nov. 17, 1942 2,306,945 Pebron Dec. 29,1942 2,309,903 Hume Feb. 2, 1943 2,367,844 vCurno Jan. 23, 1945 2,371,224 Cumfer Mar. 13,1945 2,393,347 Stuart et al. Jan. 22, 1946 2,405,909 Smith et al. Aug. 13, 1946 2,447,163` Dean'et al Aug. 17, 1948 "2,539,814 Chernack Jan. 30, 1951 FQREIGN PATENTSy Number Country Date 283,035 Great Britain Jan. 5, 1923 

7. A METHOD OF FORMING PIPE WHICH IS TO BE LAID ALONG THE GROUND, COMPRISING THE STEPS OF FORMING A CONTINUOUS TUBULAR LINER OF SHEET METAL ABOUT A HORIZONTAL MANDREL WHILE SIMULTANEOUSLY MOVING THE MANDREL WITH RESPECT TO THE GROUND IN A HORIZONTAL DIRECTION ALONG ITS AXIS AND OUT OF THE LINER THUS FORMED AND WHILE RESTRAINING THE LINER AGAINST EITHER AXIAL OR ROTATIVE MOVEMENT. 